HOW MUCH WILL IT COST?

TABLE 9-1. ESTIMATED EMISSION CONTROL COSTS^a

Control technology	Capital costs, $		Annualized costs, $
	New	Existing	New	Existing
Fume suppressants (FS)	none	none	1,100to 18,500	1,100to 18,500
Packed-bed scrubber (PBS)	39,400to 159,500	49,300to 199,400	10,400to 41,700	11,900to 47,900
Composite mesh-pad (CMP) system	29,200to 154,300	36,500to 192,900	14,500to 82,400	16,000to 90,400
Combination PBS/CMP system	62,400to 210,200	78,000to 262,800	18,300to 77,500	20,700to 86,000
Fiber-bed mist eliminator (FBME)	123,200to 540,400	135,500to 739,700	31,100to 160,400	33,000to 168,000

^a1994 dollars.1

EMISSION CONTROL COSTS

The emission control costs for each of the control technologies in the regulation are summarized in Table 9-1. Ranges of costs are presented in the table because actual control costs will vary considerably depending on the size of the facility. Also, separate cost ranges are given for new versus existing facilities because of the added cost to retrofit existing facilities. For detailed cost information, refer to the other EPA guidance materials listed in Chapter 10 of this guidebook.

What do the capital costs include? The installed capital costs include:

• the purchased cost of the control device and cost for auxiliaries, such as inlet and outlet transition zones, exhaust fans and motors, and stack;
• direct installation costs for erection, electrical panels and wiring, instrumentation and controls, and piping; and
• startup costs.
  

What do the annualized costs include?

The annualized costs include:

• direct operating costs, such as utilities;
• labor and maintenance materials;
• replacement parts;
• disposal and transportation of the used impaction material;
• indirect operating costs, such as overhead, property taxes, insurance and administration;
• capital recovery costs; and
• chromic acid recovery credits.
  

SOURCE TESTING COSTS

As discussed in Chapter 5, initial performance testing is required if you are using a control device to comply with the regulation. Ongoing testing is not required by the regulation. The estimated cost to perform the initial performance test using EPA Reference Method 306 is about $4,500 per stack if you hire an outside testing firm. However, you may choose to do the testing inhouse using EPA Reference Method 306A, which is simpler and less expensive than Method 306. The costs associated with performing one test using Method 306A are shown below:

Sampling train $ 600

Pitot, manometer, chemicals $ 50

Labor $ 180

Analysis $ 320

TOTAL COST $1,150

If you conduct your own performance test, you save an estimated $3,350 over having an outside testing firm do the work. Besides this initial cost savings, your company would also get to keep the equipment. If any additional testing is necessary, it would cost only about $510 (for labor, analysis, and chemicals) rather than an additional $4,500 per stack.

MONITORING EQUIPMENT COSTS

Stalagmometers, which are devices used to measure the surface tension of the plating bath, cost about $128.¹ Tensiometers may also be used to measure surface tension and cost about $80.² A stainless steel S­type pitot tube, used to measure velocity pressure at the inlet of a control device, costs from about $50 to $65 depending on the length of the tube. In this application, pitot tubes may have to be replaced about every 4 months due to corrosion. A pressure gauge used to monitor pressure drop (e.g., a magnehelic gauge) costs about $120. Monitoring equipment are available from numerous vendors. You may consult your fume suppressant supplier for recommendations on how to obtain the equipment.

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¹Price quote from Lurex Scientific.

²Price quote from Fisher Scientific.

MONITORING, RECORDKEEPING,

AND REPORTING COSTS

The average ongoing annual cost for monitoring, recordkeeping, and reporting is about $2,300 per facility. (Sources that have to perform initial testing will incur additional upfront costs associated with the testing and notification requirements.) This cost estimate is an average for all types and sizes of operations; small sources will incur lower costs due to the reduced requirements for these sources.

PERMITTING FEES

As discussed in Chapter 8, you may be required by the regulation to obtain an operating permit under title V of the CAA. If so, you will be charged a permit or emission fee by your State or local permitting authority when you apply for your title V permit. This fee will vary from State to State. For more information on title V operating permit fees, contact your State or local permitting authority or the EPA Regional Office for your State.

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